MACT Inspectors Checklist - Primary Aluminum · · 2015-12-10INSPECTION CHECKLIST Primary Aluminum NESHAP 40 CFR Part 63, Subpart LL ... methods and the derivation ... For Soderberg

INSPECTION CHECKLIST

Primary Aluminum NESHAP

40 CFR Part 63, Subpart LL

September, 2001

Table of Contents

1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Applicability - 40 CFR § 63.840 and 60.190. . . . . . . . . . . . . . . . . . . . . 1

3. Notifications and Reports - Checklist . . . . . . . . . . . . . . . . . . . . . . . . 2

4. Plans - Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5. Recordkeeping Requirements - Checklist . . . . . . . . . . . . . . . . . . . . . 5

6. Potline - Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

7. Anode Bake Furnace Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

8. Paste Production Plant - Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

9. New or Reconstructed Pitch Storage Tank - Checklist . . . . . . . . . . . .13

Appendix A: Footnotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B: EPA Approved Alternative Test Methods . . . . . . . . . . . . . B-1 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

1 40 CFR § 63.2 defines a major source as...“any stationary source or group of stationary sources located within a contiguous area and under common control that emitsor has the potential to emit considering controls, in the aggregate, 10 tons per year ormore of any hazardous air pollutant or 25 tons per year or more of any combination ofhazardous air pollutants...”.

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September 2001

INSPECTION CHECKLIST

Primary Aluminum NESHAP40 CFR Part 63, Subpart LL

NOTE: This checklist is a tool to evaluate compliance with the Primary AluminumNESHAP. It does not contain an exhaustive list or description of all federalenvironmental regulations that may apply to a primary aluminum facility.

1. GENERAL INFORMATION:

Date of Inspection: ___________________________________________Facility Name: _________________________________________Facility Address: _______________________________________Facility Contact: ________________________________________Contact Phone Number: _________________________________Inspector’s Name & Affiliation: __________________________________________________________________________________

Compliance Date:The affected facility’s compliance date is October 7, 1999, unless anextension was granted. Was one granted? (Y/N) ____. If yes, untilwhen? __________. (The compliance date can only be extended a

maximum of two years until October 8, 2001). Was a conditionalextension granted? (Y/N) ____. If so, what are the conditions and arethey being met?__________________________________________________________________________________________________

2. 40 CFR § 63.840 AND § 60.190 - APPLICABILITY

Except as provided in 40 CFR § 63.840(b), the requirements of Subpart LLapply to the owner or operator of each new pitch storage tank and new or existingpotline, paste production plant, or anode bake furnace associated with primaryaluminum production and located at a major source.1

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The requirements of Subpart LL do not apply to any existing anode bakefurnace that is not located on the same site as a primary aluminum reduction plant. The owner or operator shall comply with the State MACT determination establishedby the applicable regulatory authority.

An owner or operator of an affected facility (potroom group or anode bakeplant) subject to 40 CFR § 60.190 - Subpart S - Standards of Performance forPrimary Aluminum Reduction Plants, may elect to comply with either Subpart S or therequirements of Subpart LL. Section 63.844 of Subpart LL delineates emission limitsfor new or reconstructed sources covered by the MACT. The inspector shoulddetermine which regulation the source is subject to and proceed accordingly. If thesource has chosen to be regulated under Subpart S, see that subpart for theapplicable requirements.

3. NOTIFICATIONS AND REPORTS - CHECKLIST 1

Type ofNotification or

report that mustbe submitted

If you have thefollowingsituation

Submit thereport before...

FacilityCompliance

Status

CFR Citation Foot-note

Initial notificationof applicability

Existing affectedsource

2/7/98 (120days after theeffective date)

63.9(b)(2)63.850(a)(2)

Initial notificationof applicability

New orreconstructedaffected source

120 days afterinitial startup

63.9(b)(3)63.850(a)(3)

Notification ofconstruction orreconstruction

New orreconstructedmajor affectedsource withstartup after10/7/97

Construction orre-constructioncommences

63.9(b)(4)63.850(a)(4)

2

Application forapproval ofconstruction orreconstruction

New orreconstructedmajor affectedsource

ASAP beforeconstruction orre-construction

63.5(d)

Notification ofpotroom groupcomponentreplacement

An existingpotroom group

ASAP but nolater than 60days prior to construction

63.845(a)(2)(ii) 3





FacilityCompliance

Status


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Notification ofinitialperformance test

All affectedsources

60 days prior tothe scheduledtest date

63.9(e)63.850(a)(5)

Notification ofcompliancestatus

All affectedsources

60 days afterperformancetest

63.9(h)63.850(a)(6)

Notification ofintent to use HFCEMS

All affectedsources

63.850(a)(7) 4

Notification ofcomplianceapproach

Any affectedpotline ifrequested by theregulatoryauthority

Date specifiedby theregulatoryauthority

63.850(a)(8) 5

Excess emissionsreports

All affectedsources

30 days aftereach 180-dayperiod

63.10(e)(3)63.850(d)

Potroom groupexcess emissionsreport

A new, modifiedor reconstructedpotroom group

30 days afteranyperformancetest betweenthe lower andupper TF limits

63.845(f)

Performance testreports

All potlines andanode bakefurnaces

Initial testreport withnotice ofcompliancestatus; submitsubsequentreportsannually

63.850(b)





FacilityCompliance

Status


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Startup,shutdown andmalfunctionreports

All affectedsources

Within 2 days ifactions are notconsistent withSSM plan

30 days aftereach 180-dayperiod if actionsare consistentwith SSM plan

63.6(e)(3)(iv)63.10(d)(5)(ii)63.850(c)(2)

63.10(d)(5)(i)

6

See Appendix A for footnotes.

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4. PLANS - CHECKLIST

PlanName

PlanDescription

PlanAvailability

(Yes/No)

Plan Approved

(Yes/No/NotRequired)

CFRCitation

Foot-note

Site-specifictest plan

Procedures for conductingthe initial performance testand subsequentperformance tests

63.7(c)63.847(b)63.848

1

Continuousparametermonitoring plan

Parameters to bemonitored, operating limitsfor these parameters andmonitoring frequency

63.9(h)63.847(h)63.848

2

Emissionaveragingimplementationplan

Identify all sources in theaverage, the TF and POMlimits, etc.

63.846(d) 3

Engineeringplan

Describes techniquesused to address thecapture efficiency of thereduction cells (pots)

63.850(a)(8) 4

Startup,shutdown andmalfunctionplan

Describes procedures andcorrective actions to betaken during these events

63.6(e)(3)63.850(c)

5

See Appendix A for footnotes

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5. RECORDKEEPING REQUIREMENTS - CHECKLIST

Required Records Availability and Adequacy ofRecords

CFR Citation

The occurrence and duration of eachstartup, shutdown or malfunction(SSM) of process equipment

63.10(b)(2)(i)

The occurrence and duration of eachSSM of air pollution control equipment

63.10(b)(2)(ii)

All maintenance performed on the airpollution control equipment

63.10(b)(2)(iii)

Actions taken during periods of SSMwhen different from the procedures inthe SSM plan

63.10(b)(2)(iv)

All information needed to demonstrateconformance with the SSM plan

63.10(b)(2)(v)

Each period a continuous monitoringsystem (CMS) is malfunctioning orinoperative

63.10(b)(2)(vi)

All required measurements needed todemonstrate compliance with thestandard

63.10(b)(2)(vii)

All results of performance tests, CMSperformance evaluations, opacity andvisible emission observations

63.10(b)(2)(viii)

All calibration checks, adjustments andmaintenance performed on CMS

63.10(b)(2)(x) and(xi)

Documentation supporting initialnotifications and notification ofcompliance status

63.10(b)(2)(xiv)

Daily production rate of aluminum 63.850(e)(4)(i)

Daily production rate of green anodematerial placed in the anode bakefurnace(s)

63.850(e)(4)(ii)

Copy of SSM plan 63.850(e)(4)(iii)


CFR Citation

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Records of design information forpaste production plant capture systems

63.850(e)(4)(iv)

Records of design information for analternative emission control device fora paste production plant

63.850(e)(4)(v)

Records supporting the monitoring ofsimilar potlines

63.850(e)(4)(vi)

Records supporting a request forreduced sampling frequency forpotlines

63.850(e)(4)(vii)

Records supporting the correlation ofemissions measured by a continuousemission monitoring system toemissions measured by manual(reference) methods and the derivationof the alternative emissions limitderived from the measurements

63.850(e)(4)(viii)

Current implementation plan foremission averaging and anysubsequent amendments

63.850(e)(4)(ix)

Records of the daily inspection of wetroof scrubbers for control of secondarypotline emissions

63.850(e)(4)(x)

Records of the daily visual inspectionof the exhaust stack for each controldevice

63.850(e)(4)(xi)

For each potline equipped with an HFCEMS, records of information and datarequired by 63.10(c)

63.850(e)(4)(xii)

Records documenting correctiveactions taken when control deviceoperating parameter limits wereexceeded, when visible emissionsindicated abnormal operation, or whena problem was detected during aninspection of a wet roof scrubber

63.850(e)(4)(xiii)


CFR Citation

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Records documenting any POM datathat are invalidated due to theinstallation and startup of a cathode

63.850(e)(4)(xiv)

Records documenting the particulatematter and gaseous fractions of TFwhen quantified separately using anapproved test method

63.850(e)(4)(xv)

6. POTLIINE - CHECKLIST

Requirement or Inspection Item Measurement,observation,

calculation orcomment

FacilityPerformance(Yes/No/Notdetermined)


Existing potline TF emission limit 63.843(a)(1) 1, 2

Existing potline POM emission limit 63.843(a)(2) 1, 3

New or reconstructed potline TFemission limit: 0.6 kg/Mg (1.2 lb/ton)

63.844(a)(1) 4

New or reconstructed potline POMemission limit: 0.32kg/Mg (0.63 lb/ton)

63.844(a)(2) 4

Has a new potroom group been addedto an existing potline or does anypotroom group meet the definition of“modified or reconstructed potroomgroup”?

63.845 5

Does the facility employ emissionaveraging?

63.846 6

For each potline, perform monthlymonitoring of TF consisting of $3 runsfor secondary emissions and theprevious 12 month average for theprimary control system emissions

63.848(a)63.84763.849Site-specifictest plan





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Are similar potlines monitored using analternative method?

63.848(d) 7

For Soderberg potlines performquarterly monitoring of POM consistingof $1 run per month for secondaryemissions and the previous 12 monthaverage for the primary control systememissions

63.848(b)63.84763.849Site-specifictest plan

Install, operate, and maintain amonitoring device to determine the dailyweight of aluminum produced

63.848(j)

Install, calibrate, operate and maintaincontinuous parameter monitoringsystems to measure and record:

For dry alumina scrubbers -alumina flow and air flow

63.848

63.848(f)(1)

For primary wet scrubbers -water flow and air flow

63.848(f)(3)

For ESPs - voltage andsecondary current

63.848(f)(4)

For secondary wet roofscrubbers - total water flow

63.848(f)(5)(i)

For any other control device -recommend operatingparameters for the regulatoryauthority to approve and add tothe operating permit

63.848(f)63.848(m)

Alternative monitoring parameters forcontrol devices can be approved by theregulatory authority

63.848(l)





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If a continuously monitored parameterfor any control device exceeds theapproved limit >6 times in anysemiannual reporting period, it is aviolation

63.848(i)

Calibrate the continuous parametermonitoring systems according to themanufacturer’s instructions

63.848(k)

Inspect each secondary wet roofscrubber daily to ensure properoperation and record inspection results

63.848(f)(5)(ii)

Visually inspect the control deviceexhaust stack daily and record resultsof each inspection

63.848(g) 8

Initiate corrective action within one hourif the continuous parameter monitoringdevice measures a parameter outsidethe established limit(s) or if visibleemissions indicate abnormal operation

63.848(h)

Inspect pot emissions captureequipment to ensure it is operated andmaintained in a manner consistent withgood air pollution control practices forminimizing emissions

63.6(e)(1)(i) 9

How is pot ventilation rate determinedto ensure adequate capture of potemissions?

63.6(e)(1)(i) 10

Inspect primary control systemductwork for corrosion, erosion andplugging

63.6(e)(1)(i) 11

Determine average frequency of anodeeffects (#/pot-day)

63.6(e)(1)(i) 12

Inspect the positive pressure side of theprimary control system for leaks

63.6(e)(1)(i)


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7. ANODE BAKE FURNACE - CHECKLIST

Requirement or Inspection item Measurement,observation,


FacilityPerformance(Yes/No/NotDetermined)


Existing, new or reconstructedanode bake furnace TF emissionlimit: 0.20 lb/ton green anode

63.843(c)(1)63.844(c)(1)

1

Existing anode bake furnace POMemission limit: 0.18 lb/ton of greenanode

63.843(c)(2) 1

New or reconstructed anode bakefurnace POM emission limit: 0.05lb/ton of green anode

63.844(c)(2) 1

Does the facility employ emissionaveraging?

63.846 2

For each anode bake furnace,perform annual monitoring for TFand POM consisting of $3 runs

63.848(c)63.84763.849Site-specifictest plan

Install, operate, and maintain amonitoring device to determine thedaily weight of green anode materialplaced in the anode bake furnace(s)

63.848(j)

Install, calibrate, operate andmaintain continuous parametermonitoring systems to measure andrecord:

63.848

For dry alumina scrubbers -alumina flow and air flow

63.848(f)(1)

For ESPs - voltage andsecondary current

63.848(f)(4)





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For any other control device - recommend operatingparameters for the regulatoryauthority to approve and addto the operating permit

63.848(f)63.848(m)

Alternative monitoring parametersfor control devices can be approvedby the regulatory authority

63.848(l)

If a continuously monitoredparameter for any control device exceeds the approved limit >6 timesin any semiannual reporting period,it is a violation

63.848(i)


63.848(k)

Visually inspect the control deviceexhaust stack daily and recordresults of each inspection

63.848(g) 3

Initiate corrective action within onehour if the continuous parametermonitoring device measures aparameter outside the establishedlimit(s) or if visible emissionsindicate abnormal operation

63.848(h)

Inspect the negative pressure sideof the control system for airinfiltration and the positive pressureside for leaks

63.6(e)(1)(i)


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8. PASTE PRODUCTION PLANT - CHECKLIST





Install, operate and maintain anemission capture system

63.843(b)(1) 1, 2

Captured emissions routed to a drycoke scrubber

63.843(b)(2)

Has an alternate control device beenapproved by the regulatory authority?

63.843(b)(3) 3

Install, calibrate, operate, andmaintain a continuous parametermonitoring system to measure andrecord:

63.848

For dry coke scrubbers - cokeflow and air flow

63.848(f)(2)

For alternate control device -recommend operatingparameters for the regulatoryauthority to approve and add tothe operating permit

63.848(f)63.848(m)

Alternative monitoring parameters forthe dry coke scrubber can beapproved by the regulatory authority

63.848(l)

If a continuously monitored parameterfor any control device exceeds theapproved limit >6 times in anysemiannual reporting period, it is aviolation

63.848(i)


63.848(k)





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Visually inspect the control deviceexhaust stack daily and record resultsof each inspection

63.848(g) 4

Initiate corrective action within onehour if the continuous parametermonitoring device measures aparameter outside the establishedlimit(s) or if visible emissions indicateabnormal operation

63.848(h)

Inspect the negative pressure side ofthe control system for air infiltrationand the positive pressure side forleaks

63.6(e)(1)(i)


9. NEW OR RECONSTRUCTED PITCH STORAGE TANK - CHECKLIST1




CFR Citation

Design and operate an emission controlsystem to reduce POM emissions by$95%

63.844(d)

Install, operate, calibrate and maintain acontinuous parameter monitoring systemfor the control device

63.848(f) and (m)

If a continuously monitored parameter forany control device exceeds the approvedlimit >6 times in any semiannual reportingperiod, it is a violation

63.848(i)




CFR Citation

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63.848(k)

Visually inspect the control device exhauststack daily and record results of eachinspection

63.848(g)

Initiate corrective action within one hour ifthe continuous parameter monitoringdevice measures a parameter outside theestablished limit(s) or if visible emissionsindicate abnormal operation

63.848(h)

Inspect the negative pressure side of thecontrol system for air infiltration and thepositive pressure side for leaks

63.8(e)(1)(i)

1 This rule does not apply to existing pitch storage tanks (tanks in place on or before September26, 1996).

APPENDIX A

FOOTNOTES

Notifications and Reports Checklist - Footnotes

1. Table 8.1 in the Plain Language Guide to the Primary Aluminum NESHAPcontains further information on due dates for notifications and reports and Table8.2 provides information on the contents of each notification and report.

2. Several notifications are required in addition to the notice of intent to constructincluding the date construction commenced, the anticipated startup date and theactual date of startup.

3. This notice is required if the fixed capital cost of the new components exceeds50% of the fixed capital cost required to construct a comparable entirely newpotroom group.

4. The date for submission of the notification of intent to use HF CEMS is notspecified in § 63.850(a)(7). However, the source owner must receive approvalfrom the regulatory authority to use the HF CEMS as an alternative for monthlymonitoring by the procedure specified in § 63.848(d). Therefore, the notificationof intent to use the HF CEMS should be submitted with or prior to submission ofthe analysis specified in § 63.848(d).

5. If requested by the regulatory authority, the notification of compliance approachwould include the engineering plan specified in § 63.850(a)(8).

6. A report required within 2 days can be made by phone or fax followed by a letterwithin 7 days.

Plan Checklist- Footnotes

1. The site-specific test plan does not have to be submitted unless requested by theregulatory authority. However, in practice, many facilities have submitted theplan for approval since requests for alternative test methods are commonlyproposed and alternative test procedures must be approved by the regulatoryauthority. An example outline for a site-specific test plan is shown in Appendix Cof the Plain Language Guide to the Primary Aluminum NESHAP.

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2. As part of the notification of compliance status report, the continuous parametermonitoring plan should be submitted for approval by the regulatory authority. The parts of § 63.848 most relevant to the this plan include (f), (g), (j), (k) and (l).

3. The emission averaging implementation plan must be submitted to the regulatoryauthority at least six months before emission averaging will be used.

4. An engineering plan may be required by the regulatory authority as part of anotification of compliance approach.

5. The startup, shutdown and malfunction plan does not have to be submitted to theregulatory authority unless requested.

Potline Checklist - Footnotes

1. Primary Aluminum Reduction Plants by Potline TypeCWPB1 CWPB2 CWPB3 VSS1 VSS2 HSS SWPB

Alcan - Henderson,KYAlcoa -Alcoa, TNBadin, NCGooseCreek, SCMessena,NYNewburgh,INWenatchee,WANoranda -NewMadrid, MO

Alcoa -Rockdale, TXKaiser -Mead, WAOrmet -Hannibal, OHCentury - Ravenswood,WVReynolds -Troutdale,ORVanalco -Vancouver,WA

NSA -HawesvilleKY

GoldendaleAluminumCompany -Goldendale,WANorthwestAluminumCompany -The Dalles,OR

ColumbiaFalls -ColumbiaFalls, MT

Kaiser -Tacoma,WALongviewAluminumLLC -Longview,WAReynoldsMessena,NY

Eastalco -Frederick,MD AlcoaIntalcoWorks -Ferndale,WA

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2. Potline TF Limits (including emission averaging)Monthly TF limit (lb/ton of aluminum produced)

(for given number of potlines)

PotlineType

1 line 2 lines 3 lines 4 lines 5 lines $6 lines

CWPB1 1.9 1.7 1.6 1.5 1.5 1.4

CWPB2 3.0 2.9 2.8 2.7 2.7 2.6

CWPB3 2.5 2.3 2.2 2.2 2.1 2.1

VSS1 2.2 2.0 1.9 1.8 1.7 1.7

VSS2 2.7 2.6 2.5 2.5 2.4 2.4

HSS 2.7 2.5 2.4 2.4 2.3 2.3

SWPB 1.6 1.4 1.3 1.2 1.2 1.2

3. Potline POM Limits (including emission averaging)Quarterly POM Limit (lb/ton of aluminum produced)

(for given number of potlines)

Type 1 line 2 lines 3 lines 4 lines 5 lines 6 lines 7 lines 8 lines

HSS 4.7 4.1 3.8 3.7 3.5 3.5 3.4 3.3

VSS1 2.4 2.1 2.0 1.9 1.9 1.8 1.8 1.8

VSS2 3.6 3.2 3.0 2.9 2.9 2.8 2.8 2.7

4. A new potline is one for which construction commenced on or after September26, 1996. A reconstructed potline is defined in § 63.842.

5. Emission limits for new and reconstructed potlines are defined in § 63.845(e). Modified or reconstructed potroom groups are also subject to a 10% opacity limitas described in § 63.845(h).

6. If emission averaging is used, the emission limits are shown in the tables underfootnotes 2 and 3 above based on the number of potlines used in the average. Consult § 63.846 for other requirements such as preparation of animplementation plan for approval by the regulatory authority [§ 63.846(d)].

7. If an HF CEMS is used as an alternative monitoring method, the requirements of§ 63.848(d)(1) through (d)(7) must be met. The regulatory authority must

A-3

approve a methodology for correlating the HF CEMS data to the referencemethod results for comparison to the applicable emission limit.

8. In addition to visual inspections, techniques such as sticky tape, sight gages andtriboelectric bag leak detectors have been used to detect excessive particulatematter emissions from dry alumina scrubber control systems.

9. For prebake potlines, shields (hoods) should be properly placed and in goodcondition so that gaps are minimized. The pot superstructure should be sealedto prevent or minimize emissions from escaping around the anode rods and theore hoppers. Side shields and end doors should be closed at all times exceptwhen specific work is being done on the pot. Work on the pots such as replacinganodes, adding bath material and tapping aluminum should be scheduled tominimize the time the shields and doors are open.

10. Determine how the facility sets and checks the pot ventilation rate. Periodic flowmeasurement, capture efficiency testing using tracer gases, smoke bomb testsand visual evaluation of gaps and open doors are some of the methods used. IfHF CEMS for the potlines are not used, these other techniques are even morecritical to achieving and maintaining good emission capture at the pots.

11. Corrosion or abrasion holes will decrease the effectiveness of the primary controlsystem by allowing air infiltration which reduces the draft at the pots. Depositionof solids in the ducts will also reduce the capacity of the primary control system. Inquire about maintenance procedures for monitoring, maintaining and cleaningductwork.

12. Anode effects occur when the pot has an inadequate amount of aluminadissolved in the electrolytic bath. The TF emission generation rate goes upduring anode effects and most of the emissions of global warming compoundssuch as carbon tetrafluoride and carbon hexafluoride occur during anode effects. In addition, the corrective actions necessary to cure an anode effect cause moreof the emissions to escape into the potroom. Generally, the lower the number ofanode effects per pot-day and the shorter the duration of the anode effects, thebetter in terms of emissions generation, aluminum production and stability ofoperation. If available, the number of minutes in anode effect condition per pot-day is a useful measurement parameter. The trend of anode effect data overtime will help indicate how the facility is operating to minimize the emissiongeneration rate from the potlines. Anode effects are not reduced to zero becausethe opposite condition of too much alumina in the pots creates an even worseoperating condition. See EPA 430-F-98-007, February 1998, “The VoluntaryAluminum Industrial Partnership” for additional information on global warminggases from primary aluminum reduction plants.

A-4

Anode Bake Furnace Checklist - Footnotes

1. Anode bake furnace emission limits are expressed in units of pounds ofemissions per ton of green anode. Green anode means the formed anode priorto baking; therefore, the weight must be determined prior to introducing the greenanodes into the anode bake furnace.

2. If emission averaging is used, the emission limits are shown in the table belowbased on the number of anode bake furnaces included in the average. Consult §63.846 (c) and (d) for other requirements such as preparation of animplementation plan for approval by the regulatory authority.

Number of Anode BakeFurnaces

TF Emission Limit(lb/ton of green anode)

POM Emission Limit(lb/ton of green anode)

2 0.11 0.17

3 0.090 0.17

4 0.077 0.17

5 0.070 0.17

3. In addition to visual inspections, techniques such as sticky tape, sight gages andtriboelectric bag leak detectors have been used to detect excessive particulatematter emissions from dry alumina scrubber control systems.

Paste Production Plant Checklist- Footnotes

1. The definition of paste production plant in § 63.842 includes all operations frominitial mixing to final forming into briquettes, paste, or green anodes within thepaste plant, including conveyors and units managing heated liquid pitch. Therefore, the capture system must be designed to capture POM emissions fromall potential sources within the paste plant.

2. The capture system shall be installed and operated to meet the generallyaccepted engineering standards for minimum exhaust rates as published by theAmerican Conference of Governmental Industrial Hygienists in Chapters 3 and 5of “Industrial Ventilation: A Handbook of Recommended Practice.” The facilityshould have design data available to inspect for conformance to the proceduresin this handbook.

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3. If a dry coke scrubber is not used for control of paste plant emissions, the owneror operator may request approval from the regulatory authority for an alternatecontrol device if the alternate control device can achieve POM emissions lessthan 0.011 lb/ton of paste for plants with continuous mixers or 0.024 lb/ton ofpaste for plants with batch mixers. The POM emission rate shall be determinedby sampling using EPA Method 315. Disposable fiberglass filter control deviceshave been demonstrated to meet these emission limits at Goldendale Aluminumand Kaiser - Tacoma.

4. In addition to visual inspections, techniques such as sticky tape, sight gages andtriboelectric bag leak detectors can be used to detect excessive particulatematter emissions from dry coke scrubber control systems.

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APPENDIX B

EPA APPROVED ALTERNATE TEST METHODS

The Office of Air Quality Planning and Standards (OAQPS) has approved anumber of alternatives to the test methods specified in the primary aluminum NESHAP. As of July 2001, the following alternatives have been approved. Some are generalapprovals and some are plant specific. Consult the Emission Measurement Center,OAQPS for up-dated information or clarification if necessary.

1. In a Federal Register notice dated January 18, 1977, ASTM Standard MethodD3270-73T was approved as an alternative to the analytical procedures specifiedin EPA Methods 13A and 13B. (Federal Register, Volume 42, No. 17, January26, 1977) The latest version of Method 13A has incorporated this by reference insection 16.1 which reads: “Compliance with ASTM D 3270-73T, 80, 91, or 95(incorporated by reference - see § 60.17) "Analysis of Fluoride Content of theAtmosphere and Plant Tissues (Semiautomated Method) is an acceptablealternative for the requirements specified in Sections 11.2, 11.3, and 11.4.1 whenapplied to suitable aliquots of Containers 1 and 2 samples. “

2. In a letter to Alcoa dated August 8, 1996, EPA approved Alcoa Method 4075-TFand Method 4076-TF as an alternative to EPA Methods 13A or 13B.

3. In a letter to Alcoa dated July 9, 1998, EPA approved the use of scintillationanemometer technology as an alternate method to determine roof monitorvelocity from aluminum potrooms. (EPA Method 14 specifies propelleranemometers for determining roof monitor velocity from aluminum potrooms.)

4. In two letters to Alcoa dated June 17, 1999, EPA approved single point samplingas an alternative to traversing using EPA Method 13A or 13B and EPA Method14 for a specific sample point in the Method 14 sampling duct at the Alcoaaluminum plants in Badin, North Carolina and Alcoa, Tennessee.

5. In a letter to Vanalco dated December 14, 1999, EPA approved single pointsampling as an alternative to traversing using EPA Method 13A or 13B and EPAMethod 14 for a specific sample point in the Method 14 sampling duct at theVanalco aluminum plant in Vancouver, Washington.

6. In a letter to Alcoa dated December 15, 1999, EPA approved single pointsampling as an alternative to traversing using EPA Method 13A or 13B and EPAMethod 14 for a specific sample point in the Method 14 sampling duct at theAlcoa Wenatchee Works.

7. In a letter to Noranda dated August 30, 2000, EPA approved the use of a MetOne Model 50.5 sonic anemometer as an alternative to the propeller

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anemometer specified in EPA Method 14 for measuring the velocity of gasesfrom the potroom roof monitors.

8. In a memo to Dore LaPosta, EPA Region 2, dated February 20, 2001, EPAapproved single point sampling as an alternative to traversing using EPA Method13A or 13B and EPA Method 14 for a specific sample point in the Method 14sampling duct at the Alcoa-Messena aluminum plant.

REFERENCES

1. Plain Language Guide to the Primary Aluminum NESHAP - 40 CFR Part 63, SubpartLL, EPA-450/R-99-011, October 1999. Available on the EPA Unified Air Toxics Website(www.epa.gov/ttn/atw/alum/alumpg.html).

2. The Voluntary Aluminum Industrial Partnership, Pollution Prevention Program, EPA430-F-98-007, February 1998.

3. Primary Aluminum: Guideline for Control of Fluoride Emissions for Existing PrimaryAluminum Plants, EPA-450/2-78-049b, December 1979.

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Documents

MACT Inspectors Checklist - Primary Aluminum · · 2015-12-10INSPECTION CHECKLIST Primary Aluminum NESHAP 40 CFR Part 63, Subpart LL ... methods and the derivation ... For Soderberg